Refractory brick and process of making same



Sept. 1l,` 1934. 4 E. M. HARVEY ET AL 1,973,434

REFRACTORY BRICK AND PROCESS OF MAKING SAME y Filed Sept. 5, 1955Fecl-spar Clag Pgrbhg life Silica Weder l@ wn-MEN Patented Sept. 11,v1934 REFRAoToRY BRICK AND PaocEss oF G SAME Erie MasonHarvey,'Grcensboro, and John A. Boren, Pomona, N. C.

Application September 5, 1933, Serial No. 688,252

4 Claims.

The object of our invention is to provide a nove1 refractory brick; toprovide a novel process of making same; and especially to utilize anovel element, namely, pyrophyllite for the man- 5 ufacture ofrefractory bricks. We attain these and other objects of our invention bythe process hereinafter described.

Figure 1 of the drawing is a schematic diagram of the ingredients usedin manufacturing our refractory brick; and

Fig. 2 is a perspective View of the pyrophyllite which is the novelbasic element used.

We employ a nove1 basic element in the process of manufacturing ourrefractory brick. This basic element is pyrophyllite which is found inquantities suiicient for commercial purposes only in North Carolina, inMoore county and adjoining counties. By combining this pyrophyllite withother elements contained in our formula, a brick may be produced thatwill withstand sustained high temperature for an indenite period. Thisbrick when produced will be of untold commercial value for use inrelining stoves, furnaces, boilers and for other refractory uses. 4

'Ihe process used in the manufacture of this brick is as follows: Firstthe pyrophyllite must be mined, then pulverized, then mixed with otheringredients contained in the formula in proportions ranging from 5%pyrophyllite to 95% pyrophyllite. v

'I'he other ingredients are silica, clay (comprising aluminum, iron,titania, lime, magnesia, and alkalies-KzO or NazO) and feldspareitherlimespar, lime-soda spar, potash spar, soda spar, soda-lime spar.

When the'ingredients have been mixed together suicient water is added tomake a plastic compound. This compound is then run through a. die orwood mold in the desired shape of the brick. The wet brick are thenplaced in a tunnel dryer or in a building with a temperature of 110degrees .Fahrenheit where it remains from 48 to 60 hours. The brick isthen taken out and placed in kiln arid burned 5 to 6 days at a sustainedtemperature of 2300 degrees Fahrenheit. The brick is then allowed tocool under natural temperatures, which requires approximately 4 or 5days for the cooling. When this process is completed the brick is readyfor commercial use. l

Chemically, the formula is as follows: HzAlasilOlz plus SiOzAlzOz plusFezOa plus, TiOz plus CaO plus MgQ plus KzO (plus feldspar, if

used) plus H20;

The pyrophyllite described above and which constitutes the basic elementof our formula is a soft, flaky, talc-like mineral, portions of which.are of a pure cream color and very soft while other portions are of alight gray hue and not as soft and aky as the cream colored layers ofthe mineral.

It is also known to us that by the use of our formula other products canbe manufactured from pyrophyllite, consisting of a product that may beused as a substitute for porcelain, clay caskets, vaults, flue liningand all other products for refractory uses of which pyrophyllite is theprincipal basic element.

What we claim is:

1. As a new article of manufacture a refractory brick havingpyrophyllite as its basic element.

2. As a new article of manufacture a refractory brick containingpyrophyllite, silica, clay, fcldspar and water.

3. The process of making refractory brick consisting in pulverizingpyrophyllite mixing it` with silica, clay and feldspar, addingsuflicient water to make a plastic compound, molding the compound in thedesired shape of the brick, drying the brick for a suitable period,thereafter placing the brick in a kiln'and burning it for ve or six daysat a sustained extremely high temperature, and thereafter allowing thebrick to cool under natural temperatures for approximately four or vedays.

4. 'Ihe process of making refractory brickV consisting in pulverizingpyrophyllite mixing it with silica, clay and feldspar, adding sufcientwater to make a plastic. compound, molding the compound in the desiredshape of the brick, drying the brick for asuitable period, thereafterplacing the brick in a kiln and burning it for ve `or six days at asustained temperature of ap- 95 proximately 2300 degrees Fahrenheit. andallowing the brick to cool under natural temperature for approximatelyfour o r ve days.

ERIE MASON HARVEY.

JOHN A. BoREN.

